Suppressors and their methods of manufacture

ABSTRACT

A suppressor having a body and a first connector half coupled to the body, wherein the first connector half includes a first component that includes at least one channel and a first surface; and wherein the body provides a second surface, wherein a gap between the first surface and the second surface defines at least one track; wherein the gun includes a second connector half comprising at least one protrusion, wherein the protrusion and channel have corresponding shapes that allow the protrusion to be inserted through the channel and into alignment with the track, wherein the first component may be rotated with respect to the protrusion and the body to bring the protrusion out of alignment with the channel so that the first and second surfaces clamp the protrusion to thereby secure the first connector half and second connector half with respect to each other.

This application is a Continuation in Part of U.S. application Ser. No.14/138,441 which claims convention priority to New Zealand PatentApplication Nos. 605144 and 616919. In addition, this application alsoclaims convention priority to New Zealand Patent Application Nos. 626531and 630977. The entire contents of the specifications filed in supportof those applications are incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to improvements to suppressors and theirmethods of manufacture.

BACKGROUND ART

The weapons called guns use the expansion of a gas to propel aprojectile. The gas can take several forms, such as compressed airstored in a canister attached to the gun. Alternatively, fire arms are asub-type of gun, and use the expansion of a gas created by combustion topropel a projectile.

A combustible material such as gun powder is stored within theprojectile cartridge. A firing mechanism in the gun is used to ignitethe combustible material. The combustion process creates the gas.

The heat of combustion increases the temperature of the gas, whichcauses it to expand to an area of lower pressure. The primary exit fromthe gun is through the open end of the gun barrel. As a result, the gasexpands towards the open end of the gun barrel. That expansion istransferred to the projectile, propelling it out from the gun barrel.

The creation and expansion of the gas is a fast process. Accordingly,the projectile exits the gun barrel at high speed.

The generation and expansion of the gas also creates significant noisein the form of a blast wave.

That blast wave is undesirable for a number of reasons. Firstly, theblast wave creates a loud noise, which can damage a person's ears.Repeated exposure to blast waves will result in hearing loss. Secondly,the noise of the blast wave makes the use of guns unpleasant. That maybe relevant where people use guns for recreational purposes such astarget shooting. Thirdly, the blast wave can create a safety hazard. Forinstance, police may use guns around volatile gases such as thosepresent in meth labs, or the flash and noise may attract enemy fire.

Devices called suppressors or silencers are used to control the gasexpansion and thereby minimise the adverse effects it creates.

One common type of suppressor is a device which is configured to beattached to the end of a gun barrel. These devices include an inlet andan outlet, and a connecting passageway. In-use a projectile fired by thegun passes through the inlet, along the passageway, exiting thesuppressor via the outlet.

These suppressors include a series of internal baffles which definechambers within the suppressor. The gas generated during firing of theprojectile is able to expand into the chambers. The chambers arearranged such that a first chamber is comparatively larger than thevolume of the gun barrel. Accordingly, the first chamber provides alarge volume into which the gas may expand. The gas can subsequentlyexpand into adjacent chambers in the suppressor. Together, the chambersfacilitate a gradual expansion of the gas. As a result, the expansion ofthe gas is slower than were the suppressor not used, which minimises thenoise created by the blast wave.

There are numerous arrangements for baffle structures and configurationsin gun suppressors. Many of these are successful in reducing the noiseon firing of a gun. However, no known suppressor yet completely removesall noise created on firing of a gun. As a result, it would beadvantageous to have a gun suppressor having a baffle structure whichmay further reduce the noise created on firing of a gun in comparison toexisting suppressors.

In addition, it would be advantageous to have a suppressor having abaffle design which may be more suited for use with certain types ofguns and/or which takes into account variations such as caliber size,bullet type, firing mechanism and gas expansion.

There are a number of different techniques known to constructsuppressors. The most common technique is deforming sections of a rigidsheet material, and securing these together via welding. Alternativelycomponents can be formed by machining of materials to form componentsthat are then connected together by welding or fastening with threadedconnectors. These techniques are often used to form the main (outerbody) of the suppressor.

In yet another common manufacturing method a main, hollow body is firstformed. Baffles are subsequently secured to the body using techniquessuch as welding, or using spacers and threaded retainers.

Another technique involves forming, casting or machining a mono-corebaffle structure. This is subsequently secured within a hollow outerbody.

However, all of the known techniques for manufacturing suppressors havedisadvantages.

For instance, it is difficult to accurately position and weld bafflesinside the main body of the suppressor. Even if a person has sufficientskill to secure the baffles in position then it is a time consuming andcostly process.

Often, baffles are incorrectly positioned when assembled. This can leadto problems such as ineffective suppression of noise generated by theblast wave. Even worse, incorrect positioning of baffles can lead tobaffle strike, where a projectile contacts the baffle. This is a healthand safety issue and can injure the person using the gun as it wouldcause the projectile to travel in an unintended direction. It will alsodamage the suppressor and make it unusable.

In addition suppressors made as described above may not be sufficientlydurable to withstand the common forces experienced in use. The weight ofthe various components may also increase the weight of the suppressor,hindering its ease of use.

Newly developed manufacturing techniques provide opportunities formanufacturing of suppressors. For instance, selective metal melting(“SMM”), and laser metal sintering (“LMS”) which is a sub-type of SMM,are three dimensional printing technique that can be used to manufacturedifferent types of products, from a metal powder feed material

Both of SMM and LMS are additive layer manufacturing processes, thatutilise a manufacturing apparatus to convert computer generated (CAD)models into three dimensional products. A metal powder is distributedonto a substrate/support, and a laser is directed onto at least aportion of the layer of powder. The laser heats the powder so as to fuseselected individual particles together to form a portion of the product.

The laser is then disengaged and a wiper is used to deposit anotherlayer of metal powder. The laser is then again used to heat selectedpowder particles and fuse those together. The process is repeated tosubstantially create the required product. LMS techniques have been usedto manufacture components of suppressors. For instance, LMS has beenused to construct baffles for a suppressor. In that situation, thebaffles were secured to a spine. The spine and baffles were subsequentlysecured within a housing, and the housing was closed by attachment ofend walls using techniques like welding. However, those products arelimited because the individual components must subsequently beassembled. Therefore, the prior art has not maximised the efficiency ofthe manufacturing process.

In addition, the outer housing in which the spine/baffle structure wassecured was not manufactured using LMS techniques. This indicates thatmanufacturing both the housing and internal baffles using LMS techniqueswas a difficult process, and not one which was easily achieved.

It is also possible that the baffles will not provide a complete seal tocreate appropriate cavities within the housing. As a result, thesuppressors manufactured using these methods may not adequately controlexpansion of gases within the suppressor. As a result, those productsare unlikely to function as an effective suppressor.

Furthermore, the creation of a spine involves redundant material.Therefore, the suppressors manufactured using LMS to produce separatecomponents are unduly heavy. As a result they do not provide acompletely satisfactory solution to the needs for manufacturingsuppressors. Additive layer manufacturing processes, and particularlyLMS, have a number of inherent issues which have inhibited theirsuccessful use in manufacturing of products such as suppressors.

In developing a method of manufacturing a suppressor, the inventorencountered several problems. For instance, the powdered materialdeposited must be supported before it is fused. The necessary supportingmust be provided by the layer of material which has previously beenfused. Insufficient support will likely result in the build failing.These problems are most relevant where a structure is being created thatis not parallel to the build direction. This is a significant limitationon the design of products which can be manufactured using LMStechnology.

Other problems include the creation of heat stress in the suppressorduring melting of the deposited layers. These stresses create problemssuch as warping of the components of the suppressors, which meanthindered successful creation of a suppressor using LMS technology. Thismay be due to different components of the suppressor having differentthicknesses, which means that the components react differently to theheat applied to fuse the deposited powdered material. This is aparticular relevant in manufacturing suppressors, which are looking tomaximise cavity volume, have sufficient strength to withstand the forceof expanding gases, and minimise the suppressors total volume.

The inventor investigated existing applications in which LMS techniqueshave been utilised to produce complex products having a substantiallyclosed internal cavity, and internal structures within the cavity, so asto assist in developing a suppressor design using LMS techniques.However, the issues of providing sufficient support for a layer ofdeposited material prior to fusing still required significant effort andinventive contribution to solve in the particular application ofsuppressors.

For instance, PCT Publication No. WO 2008/118973 describes how tomanufacture a product having an internal baffle or structure. Thatproduct must be built from one of the four corners of the housing andhaving the housing at a 45° angle to the horizontal. That limits theorientation of the components that can be constructed inside thehousing. In fact, the manufacturing techniques described in PCTPublication No. WO 2008/118973 would not enable construction of asuppressor having function baffles therein.

Accordingly, in light of the foregoing it would be advantageous to havean improved suppressor, and method of manufacture, which addresses anyor all of the foregoing problems.

There are a number of ways that suppressors can be secured to the gunbarrel. A first attachment mechanism involves corresponding screwthreads on the suppressor and gun barrels. Rotation of the gun andsuppressor with respect to each other causes the screw threads to engageso as to secure them together. Generally, one of the gun or barrel willneed to go through at least three complete rotations (at least 1080°) tosecure or release the two objects. Many gun users find that frustratingor cumbersome.

Furthermore, screw thread fasteners suffer from a number of inherentproblems. For instance, insufficient rotation of the screw threads canlead to misalignment of the gun barrel and suppressor. This can to leadto baffle-strike which poses a health and safety risk. Even ifbaffle-strike does not occur, then misalignment of the suppressor canadversely affect accuracy of use of the gun.

Quick connect or quick attach assemblies are known to releasably securesuppressors to gun barrels. These aim to provide a comparatively quickerconnection mechanism which does not require multiple complete rotationsof the gun and/or suppressor with respect to each other.

Some common quick connect mechanisms utilise corresponding screw threadson the gun and suppressor. Alternatively, a screw thread may bepositioned on a muzzle brake, which itself is releasably attachable to agun barrel. The screw threads generally have a larger pitch, meaningthat fewer rotations are required to secure the two components together.

However, this solution is still susceptible to misalignment and theinherent problems discussed above.

Another type of quick connect system involves a gate or latch slidinglymounted to a suppressor body. The gate includes channels, which receiveprotrusions on a muzzle brake or gun barrel. However, this system is notparticularly robust and can be easily damaged. In addition, the gate isan “external” component, which increases the chance of damage.

Furthermore, many users of suppressors find the action of moving thegate unsatisfactory and prefer to use a rotational movement.

Some quick connect assemblies use bayonet style connectors on a muzzlebrake, having spring biased detents. In-use, the detents are in insertedinto corresponding channels in the suppressor. Rotation of thesuppressor and/or detents with respect to each other causes the detentsto be brought out of alignment with the channels. The biasing elementsurge the detents to bear against “stops” positioned in the channels. Theinteraction between the stops and detents provides resistance torotation of the suppressor and detents with respect to each other,thereby securing the gun and suppressor together.

However, the force to secure the suppressor to the gun barrel isentirely dependent on the spring force. Therefore, these quick connectsystems may not be suitable for use in all applications such as largecaliber guns. Alternatively, a gun user may simply not like using suchan arrangement for personal reasons.

Another form of quick connect has a non-eccentric locking portionimmovably attached to a rotatable component. To secure a gun to asuppressor, the rotatable portion is rotated, which brings thenon-eccentric locking portion into engagement with a recess or channelprovided to a gun barrel. This arrangement provides a clamping force.However, the non-eccentric locking portion will apply unequal forces tothe gun barrel e.g. the forces are not equally distributed around thecircumference of the gun barrel. This may result in less thansatisfactory attachment between the gun and suppressor.

Many quick connect systems are prone to leaking between the suppressorand the gun barrel. This can result in “blow back” of gases from thesuppressor towards the gun and user. The blow back can produce noisewhich decreases the effectiveness of the suppressor and somewhatdefeating the point of its use. In addition, the blow back can damagethe gun and/or barrel.

As a result, it would be an advantage to have an alternative quickconnect assembly for use in securing suppressors to a gun, and whichaddresses any or all of the foregoing problems.

Alternatively, it would be advantageous to have a quick connectarrangement which reduces the degrees of rotation required to secure agun and suppressor together or release them from each other.

In addition, it would be advantageous to have a quick connect assemblywhich secures a gun and suppressor together and which may reduce theoccurrence of misalignment or baffle-strike.

Alternatively, it would be an advantage to have a quick connect assemblywhich reduces or eliminates blow back on firing of a gun and/or damagewhich may be caused by same.

Alternatively, it is an object of the present invention to address theforegoing problems or at least to provide the public with a usefulchoice.

All references, including any patents or patent applications cited inthis specification are hereby incorporated by reference. No admission ismade that any reference constitutes prior art. The discussion of thereferences states what their authors assert, and the applicants reservethe right to challenge the accuracy and pertinency of the citeddocuments. It will be clearly understood that, although a number ofprior art publications are referred to herein, this reference does notconstitute an admission that any of these documents form part of thecommon general knowledge in the art, in New Zealand or in any othercountry.

Throughout this specification, the word “comprise”, or variationsthereof such as “comprises” or “comprising”, will be understood to implythe inclusion of a stated element, integer or step, or group of elementsintegers or steps, but not the exclusion of any other element, integeror step, or group of elements, integers or steps.

Further aspects and advantages of the present invention will becomeapparent from the ensuing description which is given by way of exampleonly.

DISCLOSURE OF THE INVENTION

According to one aspect of the present invention, there is provided amethod of manufacturing a suppressor having a housing with a cavity, andat least one component within the cavity, wherein the method uses aselective metal melting technique,

the method including the steps of:

-   -   (a) depositing a feed material onto a substrate;    -   (b) melting the feed material to form part of the housing;    -   (c) melting the feed material to form part of the at least one        component so that at least a portion of the component is formed        integrally to an inner wall of the housing;    -   (d) repeating steps (a)-(c) so as to substantially form the        housing and the at least one component;    -   (e) determining an angle between an underside of the at least        one component and a surface of a wall inside the housing to be        at least 10°, and more preferably in the range of 15° to 85°.

According to another aspect of the present invention, there is provideda suppressor manufactured according to the method as substantiallydescribed above.

According to another aspect of the present invention, there is provideda suppressor manufactured using a selective metal melting technique, thesuppressor including

a housing with a cavity,at least one component within the cavity, wherein at least a portion ofthe component is formed integrally to an inner surface of the housing,and wherein an angle between an underside of the component and a wallinside the housing is at least 10°, and more preferably in the range of15° to 85°.

The present specification describes a number of inventions relating tothe use of additive layer manufacturing techniques such as selectivemetal melting (“SMM”).

In preferred embodiments, the method according to the present inventionuses a SMM technique such as laser metal sintering (LMS).

Throughout the present specification references to the term “laser metalsintering” should be understood as meaning a deposition manufacturingtechnique in which layers of feed material are heated to cause selectivefusing between sections of the layers. In LMS the heat necessary to meltthe feed material is applied using a laser.

Reference will be made herein to the present inventions with LMStechniques. However, this should not be seen as limiting on the scope ofthe present invention. Other variants of SMM manufacturing techniquesare envisaged as being within the scope of the present invention.

It is also envisaged that the method can use deposition manufacturingtechniques other than LMS. For instance, the forming technique may useion beam melting techniques, or non-metal compounds such as plastics orresin materials.

As SMM and LMS techniques are known to those skilled in the art theywill not be described in full herein. Rather, the present invention(s)will now be described with sufficient information for one skilled in theart to comprehend and implement the invention(s) without any inventivecontribution and using known wisdom.

In particularly preferred embodiments, the present inventions findapplication in manufacturing suppressors, and therefore reference willbe made herein as such.

In preferred embodiments the suppressor is a device that in-use reducesthe noise and/or flash created by operation of a gun. This is as shouldbe known to one skilled in the art.

However, the suppressor could also be used with other devices in whichnoise created by gas expansion is problematic.

Throughout the present specification reference to the term “anglebetween a surface inside the housing and the at least component” shouldbe understood as referring to the angle between an imaginary plane andthe lowest point of the component. The imaginary plane and the lowestpoint on the component are both determined with reference to the builddirection for the product e.g. from the substrate used in the LMStechnique.

In a preferred embodiment, the angle is selected according to theorientation of the baffle.

In a particularly preferred embodiment, the angle is selected from thefollowing relationships:

Direction of Structure structure Example of use Angle or Radius SizeCone Towards the Baffle in a suppressor 15° to 85° centerline of theproduct Cone Away from the Baffle in a suppressor 45° to 85° for acenterline of the component having a product length of greater than 2mm; or under 15° for a component having a length less than 2 mm Lead inangle on Not Applicable Support structures from 40° or more linearsupport which a flat surface can be structure created e.g. for internalcompartmentalisation without a lower contiguous start plane Overheadflat Beginning of attachment to Must not be larger than shelves barrelor any structure 2 mm in area from support parallel to build surface Topwall - bulk Toward and To create a roof for the 4 mm radius radius(closes away from suppressor and seal the cavity structure) centerlineof while reducing use of cavity product volume by structure.

Reference through the present specification may be made to differenttypes of components such as a radius, a cone, and a column. These termsdescribe the shape of the component. The applicant has identified thatselection of the correct angle is particularly advantageous tomanufacturing components in a cavity, particularly where temporarysupport structures cannot be subsequently removed from the cavity aftermanufacture.

The angles are dependent on a number of factors such as the shape of thecomponent to be manufactured, the direction in which the component isbeing manufactured with respect to the build direction, and/or thelength and width (diameter) of the component. In addition, the thicknessof the component being manufactured, and the thickness of components onwhich the layers of material are being deposited (e.g. a relativethickness of two components) may affect angle selection.

However, one skilled in the art would be able to select the necessaryangles from those described herein without any inventive contribution orundue experimentation.

The range of angles identified herein enables successful and efficientmanufacturing of products which have internal components the shape andconfiguration of which hinder manufacturing by LMS.

In the particularly preferred embodiment, the feed material may beselected from the list of: titanium or a titanium alloys, pure titanium(TI), TI6A14V, NITI(45-55NI), TI6A17 MB, TI5A12.5FE, TI3NB13ZR,TI12MO6ZR2FE, NITICU alloys, TI15MO, TI35NB7ZR, 5TA, TI3A1 2.5V, orInconel 718.

However, the foregoing should not be seen as limiting on the scope ofthe present invention and alternatives for the feed material areenvisaged as being within the scope of the present invention.

For instance, the starter material may be any fine metal powder such ascobalt and/or chrome alloy powders, or nickel-based alloy powders.

In the preferred embodiments the housing is formed by a first end wall,a second end wall and at least one side wall and the at least onecomponent within a cavity in the housing is a baffle.

However, the foregoing should not be seen as limiting on the scope ofthe present invention. For instance the present inventions may also beuseful where it is desirable to manufacture using SMM techniques anyproduct which has a component in a cavity, and examples of suchcomponents are discussed below. This may be particularly beneficialwhere the housing is shaped so that the component cannot be removed fromthe cavity.

According to another aspect of the present invention there is providedthe use in the manufacture of a suppressor, of selective metal melting,the suppressor including

a first end wall,a second end wall,at least one side wall between the first and second end walls, whereinthe first and at least one side wall collectively define a cavity,at least one baffle within the cavity.

According to another aspect of the present invention there is provided asuppressor, including

a first end wall,a second end wall,at least one side wall connecting the first and second end walls,wherein the end walls and side wall(s) collectively define a cavity,at least one baffle inside the cavity,characterised in thatat least one of the baffles inside the cavity is formed integrally to aninner surface of the side wall(s).

According to another aspect of the present invention there is provided amethod of manufacturing a suppressor, wherein the suppressor includes afirst end wall, a second end wall, and at least one side wall connectingthe first and second end walls, and at least one baffle that is formedintegrally to an inner surface of the at least one side wall,

wherein the method includes the steps of:

-   -   (a) depositing a starter material onto a substrate;    -   (b) melting the starter material to form part of the suppressor,    -   (c) repeating steps (a) and (b) so as to substantially form the        suppressor.

Throughout the present specification reference to the term “formedintegrally” should be understood as meaning that there is no joinbetween any two parts of a suppressor manufactured using the methoddescribed herein.

Having two or more components formed integrally to each other mayimprove the strength and durability of the suppressor.

In addition, having the components formed integrally to each otherduring manufacture may reduce the need to accurately align numerouscomponents and secure these together using welding or other techniques.

It should be understood that the term “formed integrally” excludessuppressors where components are first shaped or formed, and thensubsequently secured to each other by techniques such as welding. Insuch suppressors there is a mechanical join where the two formerlyseparate components are attached together. In contrast, the presentinvention has no such join(s).

This also excludes the prior art attempts to use SMM to manufacturesuppressors. In those, components such as baffles were first formedintegrally to a separate spine, and then secured in a tube to form thesuppressors. They do not have the baffles formed integrally to an innerwall of the housing.

In particularly preferred embodiments, all components of the suppressorare formed integrally to each other. This enables the suppressors to besubstantially manufactured without any subsequent assembly, oradditional finishing.

However, the foregoing should not be seen as limiting on the scope ofthe present invention and it is also envisaged that the suppressors maybe manufactured in separate components and subsequently securedtogether.

Throughout the present specification reference to the term “side wall”should be understood as meaning at least one wall of the suppressorwhich connects the end walls.

In a particularly preferred embodiment, the side wall may besubstantially continuous.

Throughout the present specification reference to the term“substantially continuous” refers to the fact that the side wall doesnot include any apertures therein.

In these embodiments, the side wall is continuous between the first andsecond end walls.

However, the foregoing should not be seen as limiting on the scope ofthe present invention. It is also envisaged that the side wall mayinclude vents. These vents are shaped and configured so as to vent gasesexpanding within the suppressor. In these embodiments, the vents areshaped and configured so as to ensure that the sound of gases beingvented from the suppressor is reduced from that emitted without use ofthe suppressor, and preferably non-audible to humans.

In a preferred embodiment, suppressors according to the presentinvention include a fastener.

Throughout the present specification reference to the term “fastener”should be understood as meaning a component configured to secure thesuppressor to a gun.

Throughout the present specification reference to the term “baffle”should be understood as meaning a wall inside the cavity.

In preferred embodiments, the baffle is substantially cone shaped.Accordingly, the angle at which the baffle is constructed is selectedaccording to the orientation of the baffle, whether being built frominside to outside, and the angles discussed herein.

However, the baffle may also be a flat wall or structure. Therefore theforegoing should not be seen as limiting on the scope of the presentinvention.

In a preferred embodiment, the present inventions include two or morebaffles inside the cavity.

In particularly preferred embodiments, each of the baffles are formedintegrally to an inner surface of the side wall.

Each baffle, in combination with the side wall, end wall(s), and/oranother baffle define chambers within the cavity.

In preferred embodiments the suppressors according to the presentinvention include an inlet and an outlet.

Throughout the present specification reference to the term “inlet”should be understood as meaning an opening in the suppressor throughwhich a bullet may enter the suppressor.

Throughout the present specification reference to the term “outlet”should be understood as meaning an opening in the second end wallthrough which a bullet may exit the chamber.

In preferred embodiments the inlet and outlet are aligned with eachother such that a bullet can pass through the inlet, travel through thepathway, and exit from the cavity via the outlet.

Throughout the present specification reference to the term “pathway”should be understood as meaning a path through which a bullet may travelbetween the inlet and the outlet.

Therefore, in embodiments where the suppressor includes two or morebaffles then each of the baffles includes an aperture. The apertures areeach aligned with each other, the inlet and the outlet.

In a particularly preferred embodiment the pathway lies substantiallyalong a longitudinal axis of the suppressor that is on the centre lineof the suppressor.

However, the foregoing should not be seen as limiting on the scope ofthe present invention. It is also envisaged that the pathway may beoff-centre from the central longitudinal axis of the body in order toallow a lower profile for the gun and suppressor in use. Furthermore,this may minimize the suppressor hindering a user's line of sight.

In an alternate embodiment the suppressors according to the presentinvention are asymmetrical.

Throughout the present specification reference to the term“asymmetrical” should be understood as meaning that the suppressor isnot symmetrical about an imaginary plane extending along itslongitudinal axis and that is substantially horizontal in thesuppressor's normal in use orientation.

Having an asymmetrical suppressor enables the components of thesuppressor to be provided substantially in line with or below the gunbarrel when the suppressor is in use. As a result, this may minimise theamount of the suppressor which is in a user's line of sight. However,the suppressor still has sufficient baffles and chamber volume tosuppress noise produced by the gun to a desired level.

In a preferred embodiment, suppressors according to the presentinvention include a grip. Throughout the present specification referenceto the term “grip” should be understood as meaning a componentconfigured to facilitate attaching the suppressor to a gun.

In a particularly preferred embodiment the grip is at least one or moreridges on an outer surface of the body of the suppressor. In-use theridges facilitate a person gripping the body so as to rotate thesuppressor to thereby connect or release the suppressor from the gun.

The ridges facilitate a person rotating the suppressor sufficiently thatit is tightly secured to the gun. In addition, the ridges facilitate theperson rotating the suppressor so as to disengage the gun. That may beuseful where a suppressor has been tightly secured to a gun.

However, it is also envisaged that the grip may take other forms such asa handle extending away from the body of the suppressor. As a result,the foregoing should not be seen as limiting on the scope of the presentinvention.

In a particularly preferred embodiment, the fastener may be a fastenerhalf forming part of a quick connect. The term “quick connect” is a termof the art, referring to an assembly to attach two objects together thatdoes not require multiple rotations of more than a nominal angle tosecure the objects together. In contrast, a standard screw threadfastener for use in a suppressor generally requires about 15-18 fullturns (15 to 18×360°) to achieve a secure attachment.

In these embodiments, a fastener half of the quick connect is locatedwithin the overlap channel of the fastener (as is discussed below) e.g.the fastener half is within the length of the suppressor. However, thefastener half could also protrude beyond the end of the suppressor.

Other embodiments for the fastener are also envisaged. For instance, thefastener may be a screw thread complementary to a corresponding screwthread on a gun barrel or a fitting secured on a gun barrel.

In these embodiments, the screw thread has a pitch and lengthcorresponding to a screw thread on the barrel of a gun with which thesuppressor is used. The aspects of the screw thread are as should beunderstood by one skilled in the art.

The foregoing should not be seen as limiting on the scope of the presentinvention. It is also envisaged that the fastener can take other formsincluding twist lock type connectors, spring biased detents, orfastening assemblies having fittings configured to be secured over theend of a gun barrel.

In a preferred embodiment, the present invention includes a muzzlebrake.

Throughout the present specification reference to the term “muzzlebrake” should be understood as meaning a component attached or formedintegrally to a gun barrel and which assists in controlling expansion ofgases generated during firing of the gun to thereby reduce recoil. Theterm “muzzle brake” is as should be understood by one skilled in theart.

In a particularly preferred embodiment, the muzzle brake is a separatecomponent configured to be secured to an end of a gun with which thepresent invention is utilised.

In a particularly preferred embodiment, the muzzle brake includes afastener half that is configured to engage with a complementary fastenerhalf on the suppressor. The fasteners halves together form a quickconnect as discussed herein.

The inventor has identified that use of a muzzle brake is particularlyadvantageous in providing further control of gas expansion within thesuppressors according to the present invention. The present inventionsfacilitate provision of a muzzle brake using LMS techniques.

However, the foregoing should not be seen as limiting on the scope ofthe present invention. It is also envisaged that the suppressor may notinclude a muzzle brake, or that the muzzle brake may be formedintegrally into the barrel of a gun.

Furthermore, utilising LMS manufacturing techniques it is possible toprovide a muzzle brake in combination with a fastener half of a quickconnect. Previously, it has not been possible to utilise the combinationof a muzzle brake and quick connect in combination for reflex stylesuppressors. Using prior art techniques, it was impossible to providethe muzzle brake within reflex type suppressors. Therefore the muzzlebrake would extend from the end of the suppressor and would lengthen thesuppressor which creates different problems.

In preferred embodiments, the present invention may include an overlapchannel.

Throughout the present specification reference to the term “overlapchannel” should be understood as meaning a channel configured to receiveand overlap part of a gun barrel.

Use of an overlap channel enables provision of chambers within thesuppressor which, when the suppressors are secured to a gun, arepositioned so as to overlap a portion of the length of the gun barrelSuppressors having these channels are often called “reflex-style”suppressors. The overlap channel is useful to reduce the overall lengthof a gun and suppressor secured together. That in turn is useful toreduce the instances of baffle strike by providing a longer concentricmating surface to reduce potential misalignment of the gun andsuppressor.

Preventing misalignment of the gun barrel and suppressor also helps toreduce the force which the suppressor experiences in use, therebyreducing wear and tear or damage to the suppressor.

Furthermore, the use of an overlap channel ensures that the centre ofgravity of a gun with a suppressor secured thereto is closer to the gunhandle. As a result, the turning moment of the weight is reduced, makingthe gun and suppressor combination easier to use.

In a preferred embodiment, the suppressor includes a double wallstructure.

Throughout the present specification reference to the term “double wallstructure” should be understood as referring to at least an inner and anouter wall.

The outer wall provides the aesthetic appearance and structural supportfor the suppressor. The inner wall is a pressure vessel which defineschambers within which a gas can expand the outer wall defines at leastone cavity (gap) between itself and the inner wall.

The double layer wall arrangement provides insulation to prevent heattransfer from the chambers in which a gas expands to the outer surfaceof the suppressor. Therefore, a user is less likely to burn their handon touching the suppressor after use. In addition, the double layer wallhelps to eliminate mirage in optics from heat generated by use of thesuppressor. Accordingly, the utilisation of a double layer wall assistsin providing a suppressor having improved safety characteristics.

According to another aspect of the present invention, there is provideda system to reduce the noise created on firing a gun, the systemcomprising

a suppressor having a body and a first connector half coupled to thebody, wherein the first connector half comprisesa first component that includes at least one channel and a firstsurface; and wherein the body provides a second surface, and wherein agap between the first surface and the second surface defines at leastone track;wherein the gun includes a second connector half comprising at least oneprotrusion,wherein the protrusion and channel have corresponding shapes that allowthe protrusion to be inserted through the channel and into alignmentwith the track,and wherein the first component may be rotated with respect to theprotrusion and the body so as to bring the protrusion out of alignmentwith the channel so that the first and second surfaces clamp theprotrusion to thereby secure the first connector half and secondconnector half with respect to each other.

According to another aspect of the present invention there is provided agun,

wherein the gun includes at least one protrusion,wherein the at least one protrusion has a shape corresponding to achannel in a suppressor that allows the protrusion to be insertedthrough the channel and thereby be brought into alignment with a trackdefined by a first surface and a second surface.

According to another aspect of the invention there is provided asuppressor, having a body and a first connector half coupled to thebody, wherein the first connector half comprises

a first component that includes at least one channel and a firstsurface; and wherein the body provides a second surface, and wherein agap between the first surface and the second surface defines at leastone track;wherein in use a protrusion on a gun can be inserted through the channeland into alignment with the track,and wherein the first component may be rotated with respect to theprotrusion and the body to bring the protrusion out of alignment withthe channel so that the first and second surfaces clamp the protrusionto thereby secure the first connector half and second connector halfwith respect to each other.

According to another aspect of the invention there is provided a muzzlebrake for use in forming a system to reduce noise created on firing of agun, the muzzle brake including

a bodya fastener configured to secure the muzzle brake to a gun barrel,wherein the at least one protrusion has a shape corresponding to achannel in a suppressor that allows the protrusion to be insertedthrough the channel and thereby be brought into alignment with a trackdefined by a first surface and a second surface of the suppressor.

According to another aspect of the invention there is provided asuppressor, including

a body formed from at least one side wall, a first end wall, and asecond end wall,wherein the first and second end walls have aligned apertures;at least one baffle within the body,wherein the baffle includes an aperture that lays along a path betweenthe aperture in the first end wall and the aperture in the second endwall,and wherein the aperture lays on a plane that is not perpendicular tothe pathway between the first aperture and the second aperture.

According to another aspect of the invention, there is provided a systemto reduce the noise created on firing a gun, the system comprising

a suppressor, anda connection system to releasably secure the suppressor to the gun,wherein the connection system comprisesa connector half that is rotatable,at least one track, andat least one protrusion,wherein the connector half can be rotated with respect to the gun barreland the suppressor to insert the protrusion into the track to secure thesuppressor to the gun.

According to another aspect of the invention, there is provided asuppressor for use in forming the system as described herein.

According to another aspect of the invention, there is provided anintermediate component for use in forming a system as described herein,the intermediate component being configured to be connected to a gun andto be engaged by a suppressor.

According to another embodiment of the invention, there is provided anintermediate component for use in forming a system as described herein,wherein the intermediate component is a flash hider and/or a muzzlebrake.

Reference herein to the term “connector half” should be understood asmeaning a component that can engage or otherwise interact with anothercomponent, to facilitate forming of a system as described herein.

In embodiments, a connector half may take various forms or includedifferent features. Accordingly, discussion herein should not be seen aslimiting. Different terms may be used herein to refer to a connectorhalf, such as for instance “first component” or “second component” etc.

Reference may be made to locked position and release locked position.These terms should be understood as being respectively a position orconfiguration for a connector half/halves in which they do or do notsecure a suppressor to a gun respectively. In other words, the lockedposition is a configuration for a connector half in which it engagesanother connection half or other component of a connection system, tosecure a suppressor to a gun. The converse is true for the releaseposition.

Reference may be made to a quick connect, this should be understood asmeaning an assembly of components and/or system to facilitatecomparatively quick connection of a suppressor to a gun. For instance,the quick connects may reduce the degrees through which a component mustbe rotated to be secured to (and/or release from) a gun.

BRIEF DESCRIPTION OF THE DRAWINGS

Further aspects of the present invention will become apparent from theensuing description which is given by way of example only and withreference to the accompanying drawings in which:

FIG. 1 is a side “look through” view of a first embodiment of asuppressor according to one aspect of the present invention;

FIG. 2 is a cross sectional view through section C-C in FIG. 1;

FIG. 3 is a cross sectional view of another embodiment of a suppressoraccording to the present invention;

FIG. 4 is a perspective view of an alternative embodiment of asuppressor according to the present invention;

FIG. 5A is a first end on perspective view of another embodiment of asuppressor according to one embodiment of the present invention;

FIG. 5B is a second end on perspective view of the suppressor shown inFIG. 5A;

FIG. 6 is a cross-sectional view of FIG. 5A;

FIG. 7 is a view of an LMS system for use with the present invention;

FIG. 8 is a flow chart showing the steps that can be used in a method ofmanufacturing a suppressor,

FIG. 9A is a bottom perspective view of a non-symmetrical suppressoraccording to another aspect of the present invention;

FIG. 9B is an end on view of the suppressor of FIG. 9A;

FIG. 9C is a side cross sectional view of the suppressor of FIGS. 9A and9B;

FIG. 9D is a close up end cross sectional view of a suppressor of FIGS.9A-9C showing the dual wall construction;

FIG. 10A is a side view showing a muzzle brake adjacent to a suppressorwith which it is used;

FIG. 10B is a side view showing the muzzle brake and suppressor of FIG.10A engaged together,

FIG. 10C is a close up side view of the muzzle brake shown in FIG. 10A;

FIG. 10D is a perspective view of the muzzle brake shown in FIGS. 10A-C;

FIG. 10E is a second perspective view of the muzzle brake shown in FIGS.10A-C;

FIG. 11A is a view showing position of fastener halves of a quickconnect prior to engagement;

FIG. 11B is a view of FIG. 11A showing position of fastener halves of aquick connect in an engaged position;

FIG. 12 is a side cross sectional view of a suppressor design that wouldnot successfully build using LMS techniques;

FIG. 13 is a side cross sectional view of a further embodiment of asuppressor according to the present invention

FIG. 14A is a side view of a further embodiment of a suppressoraccording to the present invention;

FIG. 14B is a side cross sectional view through section A-A in FIG. 14A;

FIG. 14C is a side cross sectional view through section B-B in FIG. 14A;

FIG. 14D is a cross sectional view through section C-C in FIG. 14A;

FIG. 14E is a close up view of the detail D in FIG. 14D;

FIG. 14F is a close up view of detail E in FIG. 14C;

FIG. 15 is a side view of components of a connection system according toan embodiment of the invention;

FIG. 16 is a side cross sectional view of FIG. 1;

FIG. 17 is a side view showing components of a connection systemaccording to an embodiment of the invention secured together,

FIG. 18 is a cross sectional view of FIG. 17;

FIG. 19 is a line through section C-C shown in FIG. 18;

FIG. 20 is an end view of component of a connection system according toan embodiment of the invention;

FIG. 21 is a view through section L-L shown in FIG. 20;

FIG. 22 is a close up view of detail M shown in 21;

FIG. 23 is a side view of FIG. 20;

FIG. 24 is a view through detail K-K shown on FIG. 23;

FIG. 25 is a view through section R-R shown in FIG. 20;

FIG. 26 is a view through section T-T shown in FIG. 25;

FIG. 27 is a close up view of detail U shown in FIG. 26;

FIG. 28 is a side view of components of a connection system according toan embodiment of the invention;

FIG. 29 is a view through section C-C shown in FIG. 28;

FIG. 30 is a view through section F-F shown in FIG. 28;

FIG. 31 is a view through section H-H shown in FIG. 28;

FIG. 32 is a side view of components of the connection system of FIGS.28 to 31 secured together,

FIG. 33 is a view through section A-A shown in FIG. 32;

FIG. 34 is an end of view of FIG. 32;

FIG. 35 is a close up view of detail B shown in FIG. 33;

FIG. 36 is a view through section E-E shown in FIG. 33;

FIG. 37 is a view through section D-D shown in FIG. 33;

FIG. 38 is a view through section M-M shown in FIG. 37;

FIG. 39 is a side view of components of a connection system according toan embodiment of the invention;

FIG. 40 is a side view of FIG. 39 showing components of the connectionsystem secured together,

FIG. 41 is a view through detail section B-B shown in FIG. 40;

FIG. 42 is a view through section E-E shown in FIG. 40;

FIG. 43 is a view of section J-J shown in FIG. 39;

FIG. 44 is a close up view of detail F shown in FIG. 41;

FIG. 45 is a view of the connection system shown in FIG. 39 after firingof a weapon;

FIG. 46 is a view of detail G shown in FIG. 45;

FIG. 47 is a look-through view of an embodiment of a suppressoraccording to an embodiment of the invention;

FIG. 48 is a side cross sectional view through the suppressor of FIG.47;

FIG. 49 is a view through A-A shown on FIG. 48;

FIG. 50 is a view through section C-C shown in FIG. 47;

FIG. 51 is a view through section E-E shown in FIG. 47;

FIG. 52 is a view through section B-B shown in FIG. 47;

FIG. 53 is a view through section F-F shown in FIG. 47;

FIG. 54 is a look-through view of a suppressor according to anembodiment of the invention;

FIG. 55 is a view of through section B-B in FIG. 47;

FIG. 56 is a view through section E-E in FIG. 47;

FIG. 57 is a side cross sectional view of the suppressor of FIG. 47;

FIG. 58 is a view through section A-A in FIG. 57;

FIG. 59 is a view through section C-C in FIG. 58;

FIG. 60 is a view through section H-H in FIG. 57;

FIG. 61 is a view of section G in FIG. 56;

FIG. 62 is a view of section F in FIG. 57;

FIG. 63 is a side view of a gun and connection system according to FIGS.15 to 27;

FIG. 64 is a close up perspective view of a section of FIG. 63;

FIG. 65 is a side view of part of an alternate connection systemaccording to an embodiment of the invention;

FIG. 66 is an end on view of the connection system of FIG. 65 in arelease (unlocked) position;

FIG. 67 is a view through section A-A in FIG. 66;

FIG. 68 is an end on view of the connection system of FIG. 65 in anengaged (locked) position;

FIG. 69 is a view of section B-B in FIG. 68;

FIG. 70 is a first perspective view of a component of an embodiment ofthe invention;

FIG. 71 is a first side view of FIG. 71;

FIG. 72 is a first exploded perspective view of the components of anembodiment of the invention;

FIG. 73 is a second perspective view of FIG. 73;

FIG. 74 is an exploded view of a connection system according to anembodiment of the invention;

FIG. 75 is an end on view of an assembled connection system according tothe embodiment of FIG. 74;

FIG. 76 is a view through section A-A shown in FIG. 75;

FIG. 77 is a view through section D-D shown in FIG. 75;

FIG. 78 is a view through section B-B shown in FIG. 76;

FIG. 79 is a view through section C-C shown in FIG. 76;

FIG. 80 is an end on view of a component of a connection systemaccording to the embodiment of FIG. 75;

FIG. 81 is a side view of FIG. 80;

FIG. 82 is a view through section E-E shown in FIG. 80;

FIG. 83 is a perspective view of a component of connection systemaccording to the embodiment of FIG. 75;

FIG. 84 is a side view of a latching arm forming part of the embodimentof FIG. 75;

FIG. 85 is a second side view of a latching arm;

FIG. 86 is a first perspective view of the latching member of FIGS. 84to 85;

FIG. 87 is a second perspective view of the latching member of FIGS. 84to 86;

FIG. 88 is an end on view of a connection system according to anembodiment of the invention;

FIG. 89 is a view through section A-A shown in FIG. 88;

FIG. 90 is a view through section C-C shown in FIG. 88;

FIG. 91 is a view through section B-B shown in FIG. 88;

FIG. 92 is a view through section D-D shown in FIG. 88;

FIG. 93 is an end on view of a second component of the embodiment ofFIG. 88;

FIG. 94 is a side view of FIG. 93;

FIG. 95 is a view through section E-E shown in FIG. 93;

FIG. 96 is a perspective view of a latching arm forming part of theconnection system of FIG. 88;

FIG. 97 is a bottom perspective view of FIG. 98;

FIG. 98 is a side view of FIG. 96;

FIG. 99 is a second side view of FIG. 96;

FIG. 100 is an end on view of a connection system according to anembodiment of the invention in an unlocked configuration;

FIG. 101 is a view through section B-B shown in FIG. 100;

FIG. 102 is a view through section C-C shown in FIG. 101;

FIG. 103 is a view through section F-F shown in FIG. 101;

FIG. 104 is an end on view of the connection system of FIGS. 100 to 103in a locked configuration;

FIG. 105 is a view through section G-G shown in FIG. 104;

FIG. 106 is a view through section H-H shown in FIG. 104;

FIG. 107 is a view through section J-J shown in FIG. 105;

FIG. 108 is an exploded parts diagram of the connection system of FIGS.100 to 107;

FIG. 109 is a perspective view of a latching arm forming part of aconnection system of FIGS. 100 to 108;

FIG. 110 is a side view of the latching arm of FIG. 109.

DETAILED DISCUSSION OF THE FIGURES

Throughout the Figures like numerals refer to like components.

Referring first to FIGS. 1 and 2, there is provided a suppressor (1).

The suppressor (1) is manufactured using a selective metal meltingtechnique such as laser metal sintering (“LMS”) techniques as arediscussed below.

The suppressor (1) is a monocoque structure with all components formedintegrally to at least one other component, therefore together.

The suppressor (1) is a substantially hollow cylinder defined by acontinuous side wall (2), a first end wall (3) and a second end wall (4)that define a cavity.

First end wall (3) has an aperture (5) into an overlap channel (6). Theoverlap channel (6) is configured to receive an end of a gun barrel (notshown).

Second end wall (4) includes an aperture (7).

A pathway, indicted by line (8) extends from aperture (5) through toaperture (7). The diameter of pathway (8) is shown by line (9) in FIG.2.

A screw thread (10) is provided at end (11) of overlap channel (6). Thescrew thread (10) is configured to engage with a corresponding screwthread on an end of a gun barrel (not shown in the Figures).

The suppressor (1) has a plurality of internal baffles (12, 13, 14, 15,16).

The baffles (12-16) separate the cavity in the suppressor into a seriesof chambers (17, 18, 19, 20, 21, 22). Each of the chambers (17-22) isdefined by a baffle (12-16), inner surface (2 b) of continuous side wall(2), inner surface (3 a) of first end wall (3), and/or inner surface (4a) of second end wall (4).

Chamber (22) acts as a primary blast chamber of the suppressor (1). Theprimary blast chamber (22) has a larger volume than chambers (17-21).

Each baffle (17-22) includes an aperture (12 a-16 a) respectively. Theapertures (12 a-16 a) are aligned with each other, and apertures (5, 7).Accordingly, the apertures (12 a-16 a) are positioned on pathway (8). Itis therefore possible for a bullet fired by gun (neither shown) totravel along pathway (8) so as to exit suppressor via aperture.

Referring now to FIGS. 5A and 5B, the suppressor (1) includes a grip inthe form of ridges (23) on an outer surface (24) of continuous side wall(2).

The ridges (23) facilitate a person rotating suppressor (1) so as tocause screw thread (10) to engage with a corresponding screw thread ongun barrel (not shown).

Second end wall (4) includes a forming surface indicated as (25). Theforming surface (25) is a ring. Inner side (26) and outer side (27) areat an angle to forming surface (25).

An internal angle between an underside of the baffles (17-22) and animaginary plane (28) from the inner surface (2B) of side wall (2) isindicated by (X). The imaginary plane (28) is substantiallyperpendicular to an inner surface of continuous side wall (2) andsubstantially parallel to the build direction.

Baffle Structures First, Second and Third Alternate Embodiments ofBaffle Structures

FIGS. 3, 4 and 6 show views of alternate embodiments of suppressors (29,30, 31) according to the present invention. Identical numbers are usedto refer to the components of suppressors (29-31) in FIGS. 3, 4, and 6that are the same as the components of suppressor described withreference to FIGS. 1 and 2. However the arrangement/orientation of thebaffles differ so as to facilitate provision of a suppressor that may bebetter suited to use with different types of guns.

Fourth Alternate Embodiment of Baffle Structures

Referring now to FIGS. 9A-9D, showing a further embodiment of asuppressor (40).

The suppressor (40) has a substantially triangular cross section as isbest shown in FIG. 9B.

The suppressor (40) has a first end wall (41), a second end wall (42), afirst side wall (43), a second side wall (44), and a third side wall(45).

First end wall (41) has an aperture (46) into an overlap channel that isshown as (47) in FIG. 10C.

The first end wall (41), second end wall (42), and side walls (43-45)define a cavity (101).

A passageway, indicated by line (49) in FIG. 9C extends from aperture(46) through the cavity and to an aperture (47) in second end wall (42).

The suppressor (40) has an inner wall (102) and the second wall (103)that collectively form a double wall structure spacers (104) hold thewalls (102, 103) apart from each other. There is a space (104) betweenthe walls (102, 103) which acts to limit or reduce heat transfer fromcavity (101) to second wall (103).

Fifth Alternate Embodiment of Baffle Structures

Referring now to FIG. 14 which is a side cross sectional view ofsuppressor (50) according to a fourth embodiment of the presentinvention.

The suppressor (50) has a housing formed by a continuous side wall (51),a first end wall (52) and a second end wall (53) which collectivelydefine a cavity.

A series of baffles (54-60) are constructed so as to be integral to aninner surface of the side wall (2 b). This is as discussed above inrelation to FIGS. 13A, 13B, and 13C.

The suppressor (50) includes a series of fins (61-67) within the cavity.The fins (61-67) are all identical to each other and spaced apart alongthe length of the suppressor (50). Therefore only fin (61) will bedescribed herein.

The bottom edge (68) of fin (61) has no support underneath. Thereforethe fin (61) must be constructed out from inner surface (2 b) of sidewall (2) and downwards. As a result, fin (61) is constructed in areverse direction e.g. downwards with respect to the build direction.

The fin (61) is generally a spiral that extends along the length of thesuppressor (50), that wraps around an inner surface (2 b) of the sidewall (2). In addition, the spiral twists so that inner edge, being theedge of the spiral closest to the centre line of the suppressor (50) islower than the corresponding point on outer edge formed integrally tothe inner surface of side wall.

The shape and orientation of the fin (61) is such that the angles onside between edges of the fin and the inner wall are not equal, onebeing less than 90 degrees, and the other being greater than 90 degrees.

The fins (61-67) are orientated so that expansion of gas in the cavityis not initially hindered or obstructed. However, the passage of the gasin the cavity as it returns, to try and exit through aperture (7) isdisrupted. Therefore, the fins (61-67) may collectively slow downexpansion of gas within the cavity thereby improving the operation ofthe suppressor (50).

The fins (61-67) also provide reinforcement to the suppressor. Thiscould facilitate thinner side or end walls while still achieving acomparable strength suppressor (50).

The ridges may also increase the rigidity of the suppressor (50) orotherwise reduce/eliminate vibrations in the suppressor during itsoperation. That could be useful for reducing or eliminating audiblenoises created during use of a suppressor.

Sixth Alternate Embodiment of Baffle Structures

Referring now to FIGS. 14A-14F showing another embodiment of asuppressor (80) according to the present invention.

Numerals used to describe features of the suppressor (50) are also usedto identify similar features of suppressor (80). Therefore, thosefeatures will not be described again in relation to FIGS. 14A-14F.

However, suppressor (80) also includes a second fin (62B). The secondfin (62B) is orientated counter to the fin (62). Together, the fins (62,62B) form a double helix extending along the length of the suppressor(80).

The suppressor (80) also includes a plurality of fins (81). The fins areorientated to minimise or reduce their effect on expansion of gases intothe chambers in suppressor (80). However, the fins are orientated andconfigured to hinder, and thereby slow down, the passage of gasses outof the chambers. This is achieved by having the fins orientated so as toallow a clear and uninterrupted passage past the fins (81) as the gasinitially expands into a chamber, yet the fins (81) provide a surfaceagainst which the expanding gas abuts to thereby create turbulence andslow down the gases expansion.

Therefore the fins (81) may improve the ability of suppressor (80) toreduce the noise caused by firing a gun with which the suppressor (81)is used.

In the embodiment shown in FIGS. 14A-14F the fins (81) and are at anangle of 60° from the build direction (indicated by arrow 106), and have60 mm pitch per revolution, a width of 1.55 mm and a thickness of 0.5mm.

Seventh Alternate Embodiment of Baffle Structures

Referring now to FIGS. 33-39 showing an embodiment of a suppressor (400)having internal baffles (410, 412, 414, 416).

The suppressor (400) is a substantially cylindrical body defined by afirst end wall (402), a second end wall (404), and a continuous sidewall (406).

The suppressor (400) includes a pathway there through to enable a bulletto travel through the suppressor from first end wall (402) and exittherefrom through an aperture in second end wall (404).

The suppressor (400) may also include a fastener half (not shown in theFigures) to secure the suppressor (400) to a gun barrel (not shown). Thefastener half may be any known fastener mechanism, or the connectionsystem described herein.

The suppressor (400) is substantially hollow, having a cavity therein.The cavity however is divided into a series of compartments defined bybaffles (410-416).

The baffles (410-416) are non-symmetrical. In addition, each baffle(410-416) includes an aperture which is aligned with the apertures inthe end walls. This facilitates a bullet travelling through thesuppressor (400).

The baffles (410-416) are formed integrally to an inner surface of theside wall (406). This may be achieved using the techniques discussed inthe present Applicant's co-pending New Zealand Patent Application No.619475.

Each aperture (410-416) is non-perpendicular to the longitudinal axis ofthe suppressor.

This is best seen in FIG. 38, being a cross sectional view of thesuppressor (400). The longitudinal axis of the suppressor (400) isindicated by line (401).

Each baffle (410-416) includes a table face (420-420). Each of the tablefaces (420-426) are non-perpendicular to the suppressor's longitudinalaxis (401).

The orientation and configuration of the apertures (410-416) and thetable faces (420-426) may assist in controlling expansion of gaseswithin the suppressor (400). For instance, without being limited to aspecific mechanism, the inventor postulates that the orientations ofthese components may assist in directing expansion of gases created onfiring a gun. This may cause or promote the gases to preferentiallyexpand within the suppressor (400) towards first end wall (402) thansecond end wall (404).

Alternatively, the table faces (420-426) may provide additionalstructure within the suppressor (400) to hinder or otherwise controlexpansion of gases therein.

Each table face (420-426) extends from a neck section (430-436)respectively. The neck sections (430-436) may assist in forming thetable faces (420-426) in desired orientations using laser metalsintering techniques.

The neck sections (430-436) provide a transition from baffles sidewalls. The baffles (410-416) are curved, and generally have the shape ofa truncated and twisted cone.

Alternate Baffle Structure

Referring now to FIGS. 40 to 48 showing an a suppressor (500) accordingto an embodiment of the invention.

The suppressor (500) has a composite internal baffle structure with bothnon-symmetrical and slant baffles.

The suppressor (500) is a substantially cylindrical body defined by afirst end wall (502), a second end wall (504), and at least one sidewall (506).

The suppressor (500) includes a pathway there through to enable a bulletto travel through the suppressor from first end wall (502) and exittherefrom through an aperture in the second end wall (504).

The suppressor (500) may also include a fastener half (not shown in theFigures) to secure the suppressor (500) to a gun barrel (not shown). Thefastener half may be any known fastener mechanism, or the connectionsystem described herein with reference to FIGS. 1-24.

The suppressor (500) is substantially hollow, having a cavity therein.The cavity however is divided into a series of compartments defined bythe baffles (510-516).

The baffles (510-518) are non-symmetrical. In addition, each baffle(510-518 includes an aperture (522-530) which is aligned with theapertures in the end walls (502, 504). This facilitates a bullettravelling through the suppressor (500).

The baffles (510-518) are formed integrally to an inner surface of thesuppressor (500). This may be achieved using the techniques discussed inthe applicant's co-pending New Zealand Patent Application No. 619475.

Each aperture (522-530) is non-perpendicular to the longitudinal axis ofthe suppressor. This is best seen in FIG. 38, being a cross sectionalview of the suppressor (500). The longitudinal axis of the suppressor(500) is indicated by line (501).

Each baffle (510-518) includes a table face (532-540). Each of the tablefaces (532-540) is non-perpendicular to the suppressor's longitudinalaxis (501).

The orientation and configuration of the apertures and the table faces(532-540) may assist in controlling expansion of gases within thesuppressor (500). For instance, without being limited to a specificmechanism, the inventor postulates that the orientations of thesecomponents may assist in directing the gases. This may cause or promotethe gases to expand within the suppressor (500) towards the first end(502 preferentially over second end (504).

Alternatively, the table faces (532-540) may provide additionalstructure within the suppressor (500) to hinder or otherwise controlexpansion of gases therein.

Each table face (532-540) extends from a neck section (542-548)respectively. The neck sections (542-548) assist in forming the tablefaces (532-540) in desired orientations using laser metal sinteringtechniques.

Neck sections (542-548) extend from baffles (510-518). The baffles arecurved, and generally have the shape of a truncated and twisted cone.

Table face (540) provides a slant baffle that extends from the necksection ( ). The table face (540) is formed integrally to an innersurface of side wall (506), for instance at points (560, 562).

A scoop (564) may be formed into baffle wall (570). The scoop (550) mayassist with directing expansion of gas in the suppressor (500) topreferentially occur within a chamber (552), rather than a chamber(504).

Muzzle Brake

Referring now to FIGS. 10A-10E showing views of a muzzle brake (70)according to an embodiment of the invention.

The muzzle brake (70) is formed using LMS techniques according to thepresent inventions and using the method described with reference ofFIGS. 7 and 8. All components of the muzzle (70) brake are formedintegrally to each one other component.

The muzzle brake (70) includes a screw thread (71). A fastener halfforming part of a quick connect is provided by a plurality of detents(72) that extend outwardly from a surface (77) of the muzzle brake (70).

The detents (72) are configured to sit within corresponding slots (73)in a suppressor (74) according to the present invention. Interactionbetween the detents (72) and the slots (73) secures the muzzle brake(70) and therefore a gun (not shown) to the suppressor (74).

The muzzle brake (70) includes a first stage indicated by (75) and asecond stage indicated by (76).

The first and second stages assist in controlling expansion of the gasforming a blast wave on firing of the gun (not shown). The first andsecond stages each comprise a plurality of slot apertures, which extendalong the length of the muzzle brake (70). Each of the apertures isorientated so as to define a “twist”.

The orientation of the twist is chosen to be orientated opposite therotation of the gasses and spin created by firing a gun with which thesuppressor (74) will be used. This helps to tighten the device onto thegun.

To the inventor's knowledge it was not previously possible tomanufacture a suppressor having a quick connect inside an overlapchannel. This is because prior art manufacturing techniques were notcapable of forming a fastener half of a quick connect at the necessarylocation. As a result, there is a unique advantage provided by use ofLMS techniques to manufacture a suppressor according to the presentinvention.

However, it was not a straight forward process to design and build amuzzle brake in a suppressor using LMS techniques. The inventor solvedthe problems which prevented manufacture of these products using theinventions described herein. Therefore, the present inventions enabledLMS manufacturing techniques to be utilised in a new and previouslyunknown application. Accordingly, the inventions facilitate providing aneasier way to connect a gun and suppressor together, while allowing adeep over-barrel design yet still controlling the expansion of gases.

It should also be appreciated that designing of the muzzle brake andquick connect to be manufactured by LMS techniques was not straightforward, and a number of issues had to be resolved.

Quick Connect Connection Systems First Embodiment of a Quick Connect

Referring now to FIGS. 10A-10E, 11A and 11B. The muzzle brake (70)includes detents (72) forming part of a quick connect.

In embodiments where the suppressor (74) is to include a quick connectthen a fastener half of the quick connect is formed into the suppressor(74).

In the embodiments shown in the Figures, the fastener half is formed byslots (73) in a lip (76) that is formed integrally. However, otherpositions for the slots (73) are possible provided that these will alignwith the detents (72).

Each of the slots (73) includes a spring biased ball bearing (not shownin the Figures).

The spring biased ball bearing is positioned within the slot (73) suchthat when the detents (72) are positioned within the slots (73), thesuppressor (74) and muzzle brake (70) can be moved rotatably withrespect to each other. This causes the detents (not shown) to slidewithin slots (73) and into a locking position. The locking position isshown in FIG. 11A. In the locking position, each spring biased ballbearing (not shown) bears against an edge of a detent (not shown). Thisprovides resistance force to detents (72) moving within slots (73).Therefore, the spring loaded ball bearing secures the muzzle brake (70)and suppressor (74) with respect to each other.

However, the spring is not so strong that it cannot be overcome by forceapplied by a user that causes the muzzle brake (70) and/or suppressor(74) to rotate with respect to each other.

The non-locking position is shown in FIG. 11A. In this, the springloaded ball bearing (not shown) does not bear against detents (72).Therefore the detents (72) can be moved from the slot (73) so as toseparate the muzzle brake (70) in the suppressor (74).

First Alternate Embodiment of a Quick Connect

Referring now to FIGS. 15 to 27 showing a connection system indicatedgenerally by (700), and which is configured to provide a quick connectto secure a gun (not shown in FIGS. 15 to 27) to a suppressor (710).

The connection system (700) includes a first connector half in the formof a muzzle brake indicated as (707). The muzzle brake (703) includes abody (704) that has in general a cylindrical shape and is hollow.

Protrusions (705, 706, and 707) extend from the outer surface of thebody (704). Each protrusion (705-707) has a first surface (705A, 705B,705C) and a second surfaces (705A, 705B, 705C) respectively. The firstsurfaces (705A, 705B, 705C) provides a front face, being the face whichis distal to the gun in use. The second surfaces (5B, 6A, 7B) provides arear face being the face which is closest to the gun in use.

The body (704) includes an aperture (708) configured to receive an endof a gun barrel (not shown in the Figures). An internal screw thread(710) inside the body (704) is configured to engage with a correspondingscrew thread on the gun barrel (not shown in the Figures). Theengagement of the screw threads secure the muzzle brake (703) to thegun.

A section (711) of the body (704) includes a radially spaced aperture(712). The apertures (712) are orientated to generally extend along thelength of the body (704).

The apertures (712) are also orientated so that they twist around thecircumference of the body (704). The orientation of the twist isselected to be counter (opposed) to the direction of the screw thread(710). Thereby, the apertures (712) may provide resistance to assist inpreventing the muzzle brake (703) loosening from the gun barrel duringuse.

The connection system includes a second connector half that comprises afirst component (713) and a second component, which is indicated as(714) in FIG. 24.

The first component (713) includes radially spaced flanges (723, 724,725) as are best shown in FIG. 24.

The separation between side edges of the flanges (723, 724 and 725)define channels (726, 727, and 728). The channels (726-728) have a shapecorresponding to protrusions (705-707) on the muzzle brake (703).Therefore, inserting the section (711) through the aperture (729)enables the protrusions (705-707) to be passed through the channels(726-728).

The flanges (723-725) have an outer surface (730, 731, 732) respectivelyand an inner surface (733, 734 and 735) respectively.

The first component (713) has a body (718) having a circular aperture(729) there through. An external screw thread (719) is formed on thebody.

The second component (714) includes an aperture (715). Therefore, thesection (711) can be inserted through the aperture (715) so as to bepositioned inside the suppressor (702). This position is as shown inFIG. 18.

An internal screw thread (716) is formed integrally the suppressor (702)towards the opening (715). Ratchet teeth (717) are formed inside thesuppressor (702) immediately inside aperture (715). The ratchet teeth(717) extend around the entire circumference of aperture (715).

The screw threads (719, 716) are reverse screw threads. Therefore,rotation of the first component (713) in an anti-clockwise directionwhen viewed from the orientation of FIG. 6 will cause the screw threads(716, 719) to engage each other so to secure the first component andsecond component (713,714) together. Rotation of the first component(713) in an anti-clockwise direction as viewed in FIG. 20 will cause thescrew threads (716, 719) to disengage to release the first component(713) from the second component (714).

The first component (713) includes at least one ratchet member (720).The ratchet member (720) is integrally formed to the second component.This forms a biasing element which is configured to urge the ratchetmember (720) towards a position in which it will engage ratchet teeth(717) when screw threads (716, 179) engage each other. The engagement ofone or more of the teeth (717) by the at least one ratchet member (720)provides resistance to rotation of the first component (713) and thesecond component (714).

However, the ratchet member (720) can be moved to a release position inwhich it disengages ratchet teeth (717) to thereby allow rotation of thefirst and second components (713, 714) with respect to each other.

The second component (714) has a plurality of protrusions (780-782). Theprotrusions (780-782) define recesses (783-785). The recess (783-785)have a shape which each corresponds to the shape of one of theprotrusions (705, 706 or 707).

An aperture (722) in the second component (714) enables the section(711) to be moved past the bearing surface (721) to be disposed insidethe suppressor (702).

The first component (713) includes a bearing surface (721). The bearingsurface (721) is a section of a cone that is concentric with thesuppressor (702).

The bearing surface (721) provides an angled surface against which thesurfaces (705A, 706A, 707A) of the protrusions bear when the connectionsystem (700) is assembled.

The inner surfaces (733-735) provide clamping surfaces which in usecooperate with bearing surface (721).

In addition, the outer surfaces (730-731) provide clamping surfaceswhich in use cooperate with second surfaces (705B, 706B, 707B).

The second surfaces (705B, 706B, 707B) are not perpendicular to thelongitudinal axis of the muzzle brake (703). Preferably, the secondsurfaces (705B, 706B, 707B) are at angle in the range of 15°-65°, andmore preferably 45° to the longitudinal axis of the muzzle crake (703).

In addition, the inner surfaces (733-735) are at an angle to thelongitudinal axis of the suppressor. The angle substantially correspondsto the angle of the second surfaces (705B, 706B, 707B). This mayfacilitate the inner surfaces (733-375) providing a clamping forceagainst the second surfaces (705B-707B). This may be beneficial tofacilitate an efficient clamping action for the connection system (1).

Referring now to FIGS. 70-73.

The first and second components (713, 714) may have double helix screwthreads. That is, each screw thread (718, 719) may be formed from a pairof intertwined screw threads, which may be generally described as adouble helix. The screw threads are labeled as (716A, 716B) and (719A,719B) respectively.

Each screw thread (716A, 716B, 719A, 719B) has a start point (716C,716D) and (719C, 719D) respectively. The start points (716C, 716D) and(719C, 719D) are positioned at distal sides of the apertures. That is,the start points (716C, 716D) and (719C, 719D) are 180° apart.

The use of double helix screw threads increases the surface area contactbetween the first component (713) and the second component (714) whenthe screw threads are engaged. As a result, the first component (713)and the second component (714) can be secured to each other with fewerrotations of the screw threads, whilst still achieving a desired surfacearea contact between the two components.

The connection system (700) can be used to secure a gun (not shown) tothe suppressor (702). To do so, the muzzle brake (703) is first securedto the gun (not shown) using screw thread (710). The first component(713) is secured to the suppressor (702) by inserting body (718) intoaperture (715). The first component (713) and suppresser (702) arerotated with respect to each other so as to cause the screw threads(716, 719) to engage each other. In doing so, ratchet teeth (717) areengaged by ratchet member (720).

Section (711) is inserted through aperture (729), body (718), andaperture (722). The section (711) is therefore disposed inside thesuppressor (702). In doing so, the protrusions (5-7) pass through thechannels (726-728). The protrusions are inserted into the recesses.

The first component (713) is rotated with respect to the muzzle brake(703). This causes the protrusions (705-707) to be brought out alignmentwith the channels (725-727). In other words, the channels (725-727)rotate and therefore the protrusions are no longer completely alignedwith the channels (725-727).

The inner surfaces (733-735) each lie on a plane that is obtuse to aplane on which the bearing surface (721) lies. Accordingly, as the firstcomponent (713) is rotated with respect to the muzzle brake (703) andalso therefore the second component (714), the inner surfaces (733-735)and bearing surface (721) interact to clamp the protrusions (705-707).

When rotation of the first component (713) is stopped, the ratchetmember (720) engages at least one of the ratchet teeth (717) to which itis adjacent. Accordingly, the ratchet member (720) and ratchet teeth(717) prevent the second component (714) and the muzzle brake (703) fromrotating with respect to each other. The ratchet provides a lockingmechanism to prevent inadvertent misalignment of the suppressor (702)with the muzzle brake (703) and thereby also with the gun.

Having a plurality of radically spaced protrusions e.g., at least two orpreferably three protrusions, may assist to more evenly distributeclamping force.

To release the suppressor (702) from the muzzle brake (703) adisengagement mechanism is used.

In the embodiment of FIGS. 15 to 20, 72 and 73, the disengagementmechanism is provided to the second component (714) in the form of aring (736). The ring (736) can rotate with respect to the secondcomponent through approximately 45 to 180 degrees, and preferably 60degrees.

The ring (736) includes a protrusion (737) per ratchet member (722).Rotation of the ring (736) with respect to the body (718) causes eachprotrusion (737) to contact an end (720A) of a ratchet member (720). Thecontact moves the at least one ratchet member (720) to a position inwhich it disengages any ratchet teeth (717) with which it may have beenengaged.

The ring (736) and protrusion (737) are visible in FIGS. 72 and 73 whichshow interaction of the protrusion (737) with the at least one ratchetmember (720).

Once the at least one ratchet member (720) has disengaged the ratchetteeth (717), continued rotation of the ring (736) causes body (718) toalso rotate. Thereby, channels (733-735) are brought into alignment withprotrusions (705-707). Accordingly, the bearing surface (721) and innersurfaces (733-735) do not clamp the protrusion (705-707) to thesuppressor (702). Accordingly, the muzzle brake (703) can be moved tocause the protrusions (705-707) to move through channels (726-728).

Thereby, the muzzle brake (703) can be released from the suppressor(702). This facilitates removing the suppressor (702) from a gun (notshown).

It should be noted that the configuration of the connection system (700)is such that the components need only be rotated through a small rangeof angles to secure and release the two components together.

Second Alternate Embodiment of a Quick Connect

Referring now to FIGS. 28 to 38 showing an embodiment of a connectionsystem generally indicated as (200).

The connection system (200) includes a first connector half in the formof a muzzle brake indicated generally as (207).

The muzzle brake (207) includes a main body (208).

An internal screw thread (210) is formed the body (208). The screwthread (210) is configured to in use engage with the corresponding screwthread on the end of a gun barrel (not shown in the Figures).

The interaction of the screw thread (210) and a corresponding screwthread on the gun barrel can in use secure the muzzle brake (207) to thegun.

The muzzle brake (207) may include apertures such as (211) which areshaped and configured so as to control or otherwise direct expansion ofgasses when a bullet is fired by a gun.

The connection system (200) comprises a second connector half generallyindicated as (213). The second connector half (213) is formed from afirst component indicated as (202), and a second component (220).

The second component (220) includes a main body (230). The main body(230) includes an aperture (232) into a channel (240), as is best seenin FIG. 16.

The second component (202) is formed integrally in a gun suppressor (notshown in FIGS. 28 to 38). The gun suppressor (not shown in FIGS. 28 to38) may be a suppressor having any known internal baffle structure.

The second component (202) includes an aperture indicated generally as(203) into a channel.

The aperture (203) is configured to receive components of a gun and/orother aspects of the connection system (200).

The second component (202) includes an internal screw thread (201)within the channel (204). A plurality of ratchet teeth (200) are formedintegrally to the second component (202), within channel (204) and closeto aperture (203).

The first second component (2202) includes an external screw thread(250) formed in the main body (13). The external screw thread (250)corresponds to internal screw thread (203) in the first component (202).

Rotation of the first component (220) and the second component (202)with respect to each other causes screw threads (201, 250) to engage tosecure the two components together.

The first component (220) includes at least one, and preferably, threeflanges (260, 262, 264). Each flange (260, 262, 264) includes a firstsurface (260A, 262A, 264A) and a second surface (260B, 262B, 264B).

The gaps between adjacent flanges (260, 262, 264) define channels (266).The channels (266) are configured to receive the protrusions (209) onthe muzzle brake (207).

The first component (220) includes two ratchet members (270A, 270B). Theratchet members (270A, 270B) are spring biased protrusion that each haveat least one tooth. Pressure applied to the ratchet members (270A, 270B)at engagement points (242, 244) causes the ratchet teeth (272) to moretowards the main body (230). This causes the ratchet members (270A,270B) to disengage any ratchet teeth with which they may be engaged.

The protrusions (209) are substantially identical to the protrusions (5,6, 7) discussed above with respect to FIGS. 1-13. Accordingly, theshape, configuration, and role of the protrusions (209) will not bediscussed herein. It should also be appreciated that the function ofconnection system (200) is substantially identical to that of connectionsystem (1) as discussed above.

However, a separate disengagement means in the form of a ring is notprovided. Rather, the disengagement means is integrally formed to thefirst component (220) forming part of the first connector half in theform of the ratchet members (270A, 270B).

The engagement points (240, 242) are provided to enable a person to movethe ratchet members (270A, 270B) to a release position in which they donot engage ratchet teeth (17). Accordingly, pressure applied toengagement portions (240, 242) overcomes the biasing elements to moveratchet members (270A, 270B) away from ratchet teeth.

Third Alternate Quick Connect

Referring now to FIGS. 65 to 73 showing a connector half (600) of aconnection system according to an embodiment of the invention.

The connector half (600) includes a body (602) having a generallycylindrical shape and being hollow. The connector half (600) includes afirst aperture (604) and a second aperture (606). The apertures (604,606) are aligned with each other and define a pathway along which abullet may travel in use.

The connector half (600) may be incorporated into a suppressor (notshown in FIGS. 65 to 73). In such embodiments, the body (602) isprovided by the suppressor.

A track (610) is formed in an outer surface (612) of the body (602). Alatch (614) is slidingly mounted in track (610). The latch is connectedto a first latching member (616) and a second latching member (618).

Body (602) includes an internal radial surface (618). Each latchingmember (616, 618) is pivotally mounted to body (602) at pivot points(620). The separation between the radial surface (619) and an underside(not visible in the Figures) of the latching members (616, 618) define atrack (622) to receive protrusions on a second connector half such asthat on a gun barrel or muzzle brake (not shown in the Figures).

The protrusions on the gun barrel or muzzle brake (not shown) provide aconnector half complimentary to connector half (600). Interaction of theconnector half (600) with the protrusions (not shown) can secure asuppressor to a gun (neither shown).

In use, sliding the latch (614) along the track (610) causes thelatching members (616, 618) to be moved to a release (non-locking)position. This opens channels (624, 626) which are shaped and configuredto receive the protrusions (not shown). This enables the protrusions tobe brought into alignment with the track (622).

Sliding the latch along the track enables the latching members to reducethe dimensions of the channels (624, 626). Thereby, the protrusions canbe secured in the track (622) to attach the suppressor to a gun.

To release the suppressor from the gun the above described process isreversed. That is, the latch (614) is moved slidingly along track (610)to increase the size of channels (624, 626). The protrusions can bewithdrawn from the track (622) to release the gun and suppressor fromeach other.

Fourth Alternate Quick Connect

Referring now to FIGS. 74 to 87 which show a fourth embodiment of aconnection system (1000) according to an embodiment of the invention.The connection system (1000) includes a first component which is formedintegrally to a suppressor (1010). The first component includes aninternal screw thread (1012), which may be a pair of intertwined screwthreads which can be described as a double helix.

A second component (1020) has an external screw thread (1022), which maybe a double helix as described above. The screw threads (1012, 1022) areconfigured to engage with each other.

The first component has an internal shoulder (1014) and at least onecolumn (1016) extending therefrom.

The first component (1010) and the second component (1020) havecorresponding teeth (not shown) and ratchet members (1024). The ratchetmembers (1024) can engage the teeth (not shown) to prevent or restrictrotation of the first component (1010) and the second component (1020)with respect to each other.

At least one latching arm (1030) is pivotally mounted to first component(1010), such as by an aperture (1032) which receives the columns (1016).

A ring (1050) is provided which can facilitate rotating the secondcomponent (1020) with respect to the first component (1010). The ring(1050) provides a sheath that at least partly surrounds the secondcomponent (1020).

In the embodiment shown in FIGS. 75-88, the ring (1050) and the secondcomponent (1020) include a plurality of intermeshed teeth which areindicated generally as (1052). The teeth have a small degree of playe.g. the teeth of the ring are larger than the teeth of the teeth of thesecond component (1052) for e.g., 2 mm. This enables the ring (1050) torotate slightly relative to the second component (1020) without causingthe second component (1020) to move.

However, the intermeshed teeth (1052) enable rotation of the ring (1050)to cause a corresponding rotation in the second component (1020). Forinstance, rotation of the ring (1050) in a first direction may cause thesecond component (1020) to rotate to move towards the first component(1010). Likewise, rotation of the ring (1050) in a second direction maycause the second component to rotate to move away from the firstcomponent (1010).

The ring (1050) includes disengagement structure (not shown in theFigures) which can engage the ratchet members (1016) to cause them todisengage the teeth (not shown) on the first component (1010) onrotation of the ring (1050) in at least the first direction. Therefore,the ring (1050) is configured to ensure that the ratchet members (1016)do not prevent the first component (1010) and the second component(1020) being rotated relative to each other when desired. However, theratchet members (1016 are still able to prevent unintentional orundesired rotation of the first component (1010) and the secondcomponent (1020) relative to each other.

The embodiment of FIGS. 75 to 88 is configured to engage tracks (1060)provided on a gun (not shown in the Figures) so as to secure thesuppressor (1010) to the gun (not shown).

In the embodiment, the tracks (1060) are provided in a flash hider(1062) as should be known to one skilled in the art. The flash hider(1062) has an internal screw thread (1064) which is configured to engagea corresponding screw thread on a gun (not shown in the Figures).

To secure the suppressor (1010) to the gun, the flash hider (1062) isinserted through apertures in the second component (1020), the ring(1050), and disposed in the suppressor (1010). The ring (1050) isrotated in a first direction. The intermeshed teeth (1052) transferrotation of the ring (1050) to the second component (1020).

Ridges (1028) on the second component (1020) contact latching arms(1030) and transfer the rotational motion of the second component to thelatching arms (1030). The latching arms (1030) are caused to pivot aboutcolumns (1016). The latching arms (1030) therefore each extend into oneof the tracks (1060).

The latching arms (1030) may be shaped or configured to mate withstructure of the flash hider (1062) forming the tracks (1060). This mayensure that the latching arms (1030) and therefore the connection system(1000) more stably and/or reliably connects the gun to the suppressor(1010).

A clamping surface (1026) of the second component (1020) presses againstthe latching arms (1030). This may assist with retaining the latchingarms (1030) in engagement with the tracks (1060).

To release the suppressor (1010) from the gun (not shown) the ring(1050) is rotated in the second direction. The disengagement structureon the ring (not shown) causes the ratchet members (1016) to disengagethe teeth on the first component (not shown). The intermeshed teeth(1052) transfer rotation of the ring (1050) to the second component(1020), causing the clamping surface to disengage the latching arms(1030).

Ridges (1029) on the second component (1020) engage the latching arms(1030) and transfer rotational motion of the second component (1020) tothe latching arms (1030). This causes the latching arms (1030) to pivotabout columns (1016) to disengage the tracks (1060). The flash hider(1062) can therefore be withdrawn from the suppressor.

Fifth Alternate a Quick Connect

Referring now to FIGS. 89 to 99 which show a connection system (1100)according to an embodiment of the invention. The connection system is avariation of the embodiment described with reference to FIGS. 74 to 88,and therefore like references in the Figures refer to like components.

In the embodiment shown in FIGS. 88 to 99 the latching arms (1070) areslidingly mounted in channels formed in the suppressor (1010). Thesecond component (1020) includes a clamping surface (1080). In use,rotation of the second component (1020) in a first direction causes theclamping surface (1080) to abut a surface (1036) on the latching arms(1030).

The clamping surface (1080) is angled inwards to create a taper towardsthe centre of the second component (1020), as is best seen in FIG. 95.The surface (1036) on the latching arms (1030) is angled to create ataper as is best seen in FIG. 97.

The clamping surface (1080) forces the latching arms (1030) towards eachother. This causes a collar (1038) on each latching arm (1030) into therecess (1060) on the flash hider (1062).

The collars (1038) on the latching arms (1030) cooperate to form a sealaround the diameter of the flash hider (1062). Therefore the connectionsystem may reduce or eliminate blow back from inside the suppressor(1020) towards a gun user.

To release the suppressor (1010) from a gun, the ring (1050) is rotatedin a second direction. To release the suppressor (1010) from the gun(not shown) the ring is rotated in the second direction. Thedisengagement structure on the ring (not shown) causes the ratchetmembers (1016) to disengage the teeth on the first component (notshown). The intermeshed teeth (1052) transfer rotation of the ring(1050) to the second component (1020), causing the clamping surface todisengage the latching arms (1030).

A biasing means (not shown in the Figures) such as one or two springsmay be provided. The biasing means are positioned and orientated to urgethe latching arms (1030) apart, and towards an open position. However,contact of the clamping surface (1080) against the surface (1036) canovercome the biasing means to enable the latches to move into the recess(1060) to thereby secure the suppressor (1010) to a gun (not shown).

Sixth Alternate Quick Connect

Referring now to FIGS. 100 to 110 which show an alternate connectionsystem (1200) according to an embodiment of the invention. Theconnection system (1200) uses similar components to the connectionsystem discussed above. Accordingly, similar references numerals in theFigures refer to similar components.

The connection system (1200) is configured to connect a suppressor(1210) to a gun (not shown in the Figures) which is provided with asingle protrusion (1212) which extends around the entire circumferenceof a gun barrel (not shown in the Figures). For instance, as shown inthe Figures, the single protrusion (1212) is provided on a muzzle brake(1214).

The muzzle brake (1214) includes a screw thread (1216) which can engagea corresponding screw thread on a gun barrel (not shown) to releasablyconnect the muzzle brake (1214) to the gun barrel.

Alternatively, it is envisaged that the single protrusion (1212) couldbe formed integrally to, or be otherwise permanently attached to, thegun barrel.

The single protrusion (1212) has a first shoulder (1211) and a secondshoulder (1218). The shoulders taper (1211, 1218) inwards to provide aridge (1219). The ridge (1219) extends around the entire circumferenceof the muzzle brake (1214). Therefore, the single protrusion is distinctto the embodiments discussed above in which a plurality of protrusionswere provided.

The suppressor (1210) includes a shoulder (1211) which in use provides aclamping surface.

The connection system (1200) includes a second component (1220) havingan external screw thread (1222) configured to engage a correspondinginternal screw thread on the suppressor (1210).

The connection system (1200) includes at least one, and preferably two,latching arms (1230, 1232). The latching arms (1230, 1232) areconfigured to engage the single protrusion (1212). The latching arm(s)(1230, 1232) are positioned between shoulder (1211) and the secondcomponent (1220).

Each latching arm (1230, 1232) includes a detent (1234). The detents(1234) are each slidingly engaged in one of tracks (1238, 1240) formedin shoulder (1211).

The tracks (1238, 1240) are shaped to guide movement of the latchingarms (1230, 1232) between a locked position in which they clamp a gunbarrel to the suppressor (1210) and a release position in which theyenable the protrusion to be inserted into or removed from the suppressor(1210). The locked position is shown in FIGS. 100-103 while the releaseposition is shown in FIGS. 104 to 107.

Each latching arm (1230, 1232) includes a shoulder (1242, 1244). Theshoulders (1242, 1244) are configured to abut an internal clampingsurface (1223) on the second component (1220) in use.

To secure a gun (not shown) to the suppressor (1210) the singleprotrusion (1212) is inserted through apertures in the second component(1220) and into suppressor (1210). The shoulder (1217) is adjacent theshoulder (1213) and ridge (1219) is between the latching arms (1230,1232) and the shoulder (1211). The second component is rotated in afirst direction with respect to the suppressor (1210), this causesclamping surface (1213) to move towards shoulder (1211).

The clamping surfaces (1213) abut the shoulders (1242, 1244). Thecontact causes the latching arms (1230, 1232) to move radially inwardstowards a central axis of the suppressor e.g., the collars on thelatching arms move towards each other. The movement of the latching arms(1230, 1232) is guided by the detents moving within the tracks.

Continued rotation of second component (1220) causes the latching arms(1230, 1232) to push single protrusion (1212) towards shoulder (1213).

The connection system is structured to create a seal to provideresistance to, or prevent, blow back of gas from within the suppressor(1210) towards the gun barrel.

The seal may be created by various structures and/or configurations. Inone embodiment, the latching arms are shaped and configured so that eachend or a collar touches an end of another collar. For instance, in theseembodiments, the collars may touch. In addition or alternatively, thelatching arms may overlap each other.

To release the suppressor from the gun, the above steps are reversed.For instance, the second component (1220) is rotated in a seconddirection. This causes detents to move along tracks, to guide thelatching arms radially outwards.

The connection system (1200) may also be provided with a biasing meanssuch as a spring (not shown). The biasing means can be configured tourge the latching arms apart from each other.

Therefore, the biasing means can ensure that the latching arm(s) aremoved towards an open position in which they do not restrict or preventthe muzzle brake being inserted into, or removed from, the suppressor(1210). Accordingly, the biasing means may make it easier to connect andrelease a suppressor from a gun.

However, in these embodiments, rotation of the second component (1220)can overcome the biasing means to move the latching arms to a lockedposition. As a result, the biasing means do not prevent assembly of asystem as described herein.

Also, as indicated, the connection system (1200) may include structureor visual indications that inform a user which direction a componentshould be rotated to secure a suppressor to, or release it from, a gun.

Nielson Decoupler

Referring now to FIGS. 39 to 46 showing a suppressor (300) according toan alternate embodiment of the invention.

The suppressor (300) includes a Nielson decoupler configured to at leastpartially reduce transfer of momentum to a firearm to which thesuppressor (300) is secured in use. The momentum may be transferred bygas created on firing a firearm contacting baffles within the suppressor(300). However, the Nielson decoupler provides a mechanism to absorb atleast a portion of the momentum transferred to the suppressor (300) inuse and thereby reduce the energy which may be transferred to thefirearm.

The suppressor includes a piston (320). The piston (320) includes screwthread (322) configured to engage a corresponding screw thread on a gunbarrel (not shown in the Figures) to thereby facilitate securing thesuppressor (300) to a gun (not shown). The piston (320) includes a body(330) which has a general cylindrical shape and is hollow. Therefore,the body (330) defines a passageway through which a bullet may travel.

The body (330) includes radially spaced apart slot apertures (340).

Protrusions (350) extend from the body (330). The protrusions (350)define peaks and troughs as are best seen in FIG. 29. The suppressor(300) is a cylindrical body having an internal cavity. Baffles (notshown in the Figures) are secured within the suppressor (300).

The body (330) includes a second series of radially spaced apart slotapertures (352). The slot apertures (352) are orientated to “twist”around the circumference of the body (330).

The suppressor (300) may have any known internal baffle structure, orutilise baffle structures discussed herein.

The suppressor (300) has a first opening (302) and a second opening(304).

The suppressor (300) includes an internal screw thread (309) as is bestseen in FIGS. 30 and 32. The screw thread (354) is configured to engagewith a corresponding screw thread (356) on a locking nut (360).

A channel is defined by a channel wall (354) that extends from internalscrew thread (354) towards an end (360) of suppressor (300).

Channel end wall (368) extends away from channel wall (364).

The channel end wall (368) includes a circular aperture (not labeled inthe Figures). The circular aperture has a shape and size correspondingto the diameter of body (330) so that the body (330) can move throughthe aperture.

To assemble the Nielson decoupler (320), an absorber in the form of acompression spring (370) is provided. In use, the spring (370) at leastpartially absorbs the gas force against the baffles created on firing ofthe gun. The compression spring (372) is positioned around the body(330) to bear against a side of the protrusions (350).

The piston (320) is inserted through the opening, moved along thechannel, and through the circular opening (not labeled) in the channelend wall (364).

The locking nut (380) is positioned about body (330) and rotated so thatscrew threads (356, 322) engage each other. This secures the piston(320) to the body (330).

This configuration is shown in FIG. 30 e.g. the spring (370) is notcompletely or substantially compressed. In other words, in thisconfiguration the spring (370) can still be further compressed ifsufficient force is applied thereto.

Referring now to FIGS. 27 & 30-32.

FIGS. 27 and 30 show views of the suppressor (300) with the spring (370)in an unloaded (non-compressed) configuration. This is the normalconfiguration.

However, on firing of a gun (not shown) to which the suppressor (300) issecured, expansion of gases within the suppressor (300) provides anurging force to move the suppressor (300) in the direction shown byarrow X in FIGS. 31 and 32. The urging force causes an end (30) ofsuppressor (300) to move along the length of body (300). It should benoted that locking nut (360) moves at a corresponding rate to end (30).This is because the locking nut (300) is not fixedly attached to thebody (330).

In-effect, channel (362) enables the separation between locking nut(360) and the protrusions (350) to be decreased. This compresses thespring (307) between the locking nut (360) and the protrusions (350).Therefore, the spring (370) can absorb gas forces imported to thesuppressor (300) on firing of the gun (not shown).

The spring (370) provides an urging force to move suppressor in adirection opposite to arrow X shown in FIGS. 31 and 32.

The protrusions (350) provide an alignment function. That is, theprotrusions (350) touch, and can slide along, an inner surface ofchannel wall (368) irrespective of the compression of spring (360).

The protrusions are also positioned with respect to the screw thread(350) to provide an alignment function. That is, the protrusions (350)will help to ensure that the suppressor body (300) does not dip or droopwhich would cause it to be misaligned with the piston (320) and therebyis substantially maintained in alignment with the gun barrel (not shownin the Figures).

Method of Manufacture

Different products according to the present invention can bemanufactured using the same method. Accordingly, one method ofmanufacturing a product is described herein.

The method is performed using an additive layering manufacturing system,the representative components of which is indicated as (32) are shown inFIG. 7.

The system (32) includes a computer programming apparatus (33) as shouldbe known to one skilled in the art. The computer programming apparatusis programmed to perform any of all of the steps of the method describedherein. In addition, the apparatus is programmed to, or may beconfigured to, performs steps in the method so as to manufacture theembodiments of the suppressors described herein.

The computer programming apparatus (33) is configured to communicatewith a laser metal sintering (“LMS”) apparatus (34).

Operation of the LMS apparatus (32) is as should be known to one skilledin the art, and therefore the specifics of the method are not reiteratedhere. However, parameters such as selection of the starter material,temperature required to achieve necessary fusing of layers of particlesof starter material etc. are as known to one skilled in the art.

Referring now to FIG. 8 showing a schematic of the steps involved inmanufacturing a product according to the present invention.

At step (35) an electronic model of a suppressor is created using amodelling package such as CAD Solid Works on computer programmingapparatus (33).

Developing the CAD model involves the step of determining a builddirection for the product. The build direction is an orientation for aproduct to be manufactured such as a suppressor with respect to asubstrate in the LMS Apparatus (34). The build direction defines theorder in which layers of the powdered material are deposited andsintered so as to form the product.

In a preferred embodiment, the build direction requires building asuppressor such as (1) from the second end wall (4).

Developing the model of a product to be manufactured involves the stepof determining the angle between various components. For instance, inmanufacturing a suppressor (1), a person would determine the anglebetween an underside of a baffle and a substantially horizontal plane(28).

In addition, internal structures inside a cavity in the product aredetermined. These will depend on the shape and configuration of theproduct to be produced. The features of the components are selectedaccording to the relationships described herein so as to ensure that theproduct can be manufactured using the LMS apparatus.

At step (36) the CAD model is separated into a number of layers of anominal thickness between 0.01 mm-0.03 mm.

The model and information on the layers is transmitted from the computerprogramming apparatus (33) in which the model is created to the LMSapparatus (34).

At step (37) a build substrate (not shown) in the Figures is provided inthe LMS apparatus (34).

The substrate provides a surface on which the product can bemanufactured.

At step (38) the LMS apparatus (34) applies a layer of a titanium oxidealloy in a powder form onto the substrate. A laser (not shown) formingpart of the LMS apparatus (34) selectively applies a laser beam toportions of the layer of titanium oxide powder deposited on thesubstrate (not shown). This causes the laser to selectively heat thetitanium oxide powder so as to fuse adjacent particles together. Thelaser heats a portion of the layered titanium oxide powder correspondingto a first layer of the model of the product generated at step (35).This forms a first sintered layer.

At step (39) a wiper (not shown in the Figures) forming part of the LMSapparatus (34) is used to apply another layer of titanium oxide powderon top of the first sintered layer.

This corresponds to the second layer of the CAD model generated at step(36).

Steps (38 and 39) are repeated so as to substantially form the product.

The formed product can be removed from the LMS apparatus (34) andseparated from the substrate (not shown).

Unsuccessful Suppressor Design

Referring now to FIG. 12 showing a suppressor (94) that is unlikely tobe successfully manufactured using LMS techniques.

The suppressor (94) is designed so that build direction indicated byarrow (95) in FIG. 12 starts from second end wall (4).

The baffles (12-14) would build successfully.

However, the suppressor (94) includes a shelf (96).

The angle (X) between an underside (97), of shelf (96) and an inner wall(2B) of the suppressor is substantially 90 degrees.

As a result, there is insufficient support for layers of the powderedfeed material deposited through a manufacturing of the suppressor (94).As a result, the shelf (96) would not successfully build using an LMStechnique.

In addition, the shelf (96) and baffle (14) integrally joined to theshelf (96), have different thicknesses. This is necessary to try toensure that sufficient material is deposited to enable building of asubsequent baffle up from the shelf (96). However, the differentthicknesses lead to thermal gradient throughout the components of thesuppressor (94). Those thermal gradients are a result of parameters ofthe LMS apparatus (34) being fixed (invariable) during the manufacturerof a particular part. As a result, it is not possible to vary the amountof energy which laser of the LMS apparatus (34) imparts to differentparts of the suppressor (94) during its manufacture. As a result, theparameters of the laser are often selected so as to provide an averagesuitable for use in preforming all parts of the suppressor any givenpart. However though, the average chosen will not work with allparticular components, meaning that selection of design features isparticularly important to successfully building of suppressors.

Aspects of the present invention have been described by way of exampleonly and it should be appreciated that modifications and additions maybe made thereto without departing from the scope thereof as defined inthe appended claims.

While the invention has been described in connection with what arepresently considered to be the most practical and preferred embodiments,it is to be understood that the invention is not to be limited to thedisclosed embodiments. On the contrary, it is intended that thespecification covers various modifications and equivalent arrangementsincluded within the spirit and scope of the invention. Also, the variousembodiments described above may be implemented in conjunction with otherembodiments, e.g., aspects of one embodiment may be combined withaspects of another embodiment to realise yet other embodiments, Further,each independent feature or component of any given assembly mayconstitute an additional embodiment.

What I claim is:
 1. A system to reduce the noise created on firing agun, the system comprising a suppressor having a body and a firstconnector half coupled to the body, wherein the first connector halfcomprises a first component that includes at least one channel and afirst surface; and wherein the body provides a second surface, andwherein a gap between the first surface and the second surface definesat least one track; wherein the gun includes a second connector halfcomprising at least one protrusion, wherein the protrusion and channelhave corresponding shapes that allow the protrusion to be insertedthrough the channel and into alignment with the track, and wherein thefirst component may be rotated with respect to the protrusion and thebody so as to bring the protrusion out of alignment with the channel sothat the first and second surfaces clamp the protrusion to therebysecure the first connector half and second connector half with respectto each other.
 2. The system as claimed in claim 1, wherein the secondconnector half is a muzzle brake secured to a gun barrel.
 3. The systemas claimed in claim 2, wherein the muzzle brake is releasably secured toa barrel of the gun.
 4. The system as claimed in claim 1, including alocking mechanism configured to prevent rotation of the first componentwith respect to the protrusion.
 5. The system as claimed in claim 4,wherein in the locking mechanism is a ratchet locking mechanismcomprising at least one ratchet member and at least one ratchet tooth.6. The system as claimed in claim 5, including a disengagement mechanismconfigured to move the at least one ratchet member to a releaseposition.
 7. The system as claimed in claim 6, wherein the disengagementmechanism comprises a ring having at least one protrusion configured toabut the ratchet member on rotation of the ring to thereby move theratchet member to the release position.
 8. The system as claimed inclaim 6, wherein the disengagement mechanism is at least one engagementpoint that enables pressure to be applied to the at least one ratchetmember to thereby move at least one ratchet member to a releaseposition.
 9. The system as claimed in claim 1, wherein the firstcomponent and the second component have complementary screw threadsconfigured to engage each other to thereby attach the first and secondcomponents to each other.
 10. The system as claimed in claim 9, whereinthe first component includes a pair of intertwined screw threads, andthe second component includes a pair of intertwined screw threads, andwherein the pairs of intertwined screw threads in use interact with eachother to secure the first and second component together.
 11. The systemas claimed in claim 10, wherein the pair of intertwined screw threads ofthe first component are a double helix.
 12. The system as claimed inclaim 1, wherein the first surface and the second surface are shaped andorientated with respect to each other so that rotation of the firstcomponent through 45-180 degrees will ensure that a sufficient portionof the protrusion extends into the track for the first and secondsurfaces to provide a clamping action.
 13. The system as claim in claim12, wherein the first surface and the second surface are shaped andorientated with respect to each other so that rotation of the firstcomponent through 60 degrees ensures that at a sufficient portion of theprotrusion extends into the track for the first and second surfaces toprovide a clamping action.
 14. The system as claimed in claim 1, whereinthe protrusion includes a forward face and a rear face, and wherein atleast the rear face is orientated at an angle with respect to thelongitudinal axis of the first connector half.
 15. The system as claimedin claim 14, wherein the first surface is shaped and orientated at anangle with respect to the longitudinal axis of the second connectorhalf, and wherein the angle of the first surface corresponds to theangle of the rear face of the protrusion.
 16. A suppressor for use inreducing the noise created on firing a gun the suppressor having a bodyand a first connector half coupled to the body, wherein the firstconnector half comprises a first component that includes at least onechannel and a first surface; and wherein the body provides a secondsurface, and wherein a gap between the first surface and the secondsurface defines at least one track; wherein in use a protrusion on a guncan be inserted through the channel and into alignment with the track,and wherein the first component may be rotated with respect to theprotrusion and the body to bring the protrusion out of alignment withthe channel so that the first and second surfaces clamp the protrusionto thereby secure the first connector half and second connector halfwith respect to each other.
 17. The suppressor as claimed in claim 16,including a locking mechanism configured to prevent rotation of thefirst component with respect to a protrusion disposed in the track. 18.The suppressor as claimed in claim 17, wherein in the locking mechanismis a ratchet locking mechanism comprising at least one ratchet memberand at least one ratchet tooth.
 19. The suppressor as claimed in claim18, including a disengagement mechanism configured to move the at leastone ratchet member to a release position.
 20. The suppressor as claimedin claim 19, wherein the disengagement mechanism comprises a ring havingat least one protrusion configured to abut the ratchet member onrotation of the ring to thereby move the ratchet member to the releaseposition.
 21. The suppressor as claimed in claim 19, wherein thedisengagement mechanism is at least one engagement point that enablespressure to be applied to the at least one ratchet member to therebymove at least one ratchet member to a release position.
 22. Thesuppressor as claimed in claim 15, wherein the first component and thesecond component have complementary screw threads configured to engageeach other to thereby attach the first and second components to eachother.
 23. The suppressor as claimed in claim 15, wherein the firstcomponent includes a pair of intertwined screw threads, and the secondcomponent includes a pair of intertwined screw threads, and wherein thepairs of intertwined screw threads in use interact with each other tosecure the first and second component together.
 24. The suppressor asclaimed in claim 23, wherein the pair of intertwined screw threads ofthe first component are a double helix.
 25. The suppressor as claimed inclaim 15, wherein the first surface and the second surface are shapedand orientated with respect to each other so that rotation of the firstcomponent through 45-180 degrees will ensure that a sufficient portionof the protrusion extends into the track for the first and secondsurfaces to provide a clamping action.
 26. The suppressor as claim inclaim 25, wherein the first surface and the second surface are shapedand orientated with respect to each other so that rotation of the firstcomponent through 60 degrees ensures that at a sufficient portion of theprotrusion extends into the track for the first and second surfaces toprovide a clamping action.
 27. The suppressor as claimed in claim 15,wherein the protrusion includes a forward face and a rear face, andwherein at least the rear face is orientated at an angle with respect tothe longitudinal axis of the first connector half.
 28. The suppressor asclaimed in claim 27, wherein the first surface is shaped and orientatedat an angle with respect to the longitudinal axis of the secondconnector half, and wherein the angle of the first surface correspondsto the angle of the rear face of the protrusion.